Method of casting in a plurality of molds



Feb. 27, 1968 w. R. FENZAN 3,370,640

METHOD OF CASTING IN A PLUHALITY 0F MOLDS Original Filed Oct. 29, 1965 3 ts-Sheet l Feb. 27, 1968 w. R. FENZAN 3,370,640

' METHOD OF CASTING IN A PLURALITY OF MOLDS Original Filed Oct. 29. 1963 3 Sheets-Sheet 2 Ja e/7.501:- ZZ/ZZL am Rik/7262f? Feb. 27, 1968 Original Filed 001; 29, 1963 w. R. FENZAN 3,370,640

METHOD OF CASTING IN A PLURALITY OF MOLDS 3 Sheets-Sheet 3 l I V I ,Pas. 1). Pas. a.

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United States Patent 3,370,640 METHOD OF CASTING IN A PLURALITY F MOLDS William R. Fenian, Akron, Ohio, assignor to Amsted Industries Incorporated, Chicago, 11]., a corporation of New Jersey Original application Oct. 29, 1963, Ser. No. 319,722, now Patent No. 3,296,665, dated Jan. 10, 1966. Divided and this application Oct. 19, 1966, Ser. No. 587,902

Claims. (Cl. 164-136) ABSTRACT OF THE DISCLOSURE Upright molds are mounted on cars and moved into and past a pouring station at which the molds are filled. Each mold is made of separable parts and power means are utilized to close the mold and move the mold into the pouring station. The molds are moved away from the pouring station after which other power means are utilized to separate the mold parts so that the cast product can be removed therefrom.

This application is a division of application Ser. No. 319,722, filed Oct. 29, 1963, now Patent No. 3,296,665.

This invention relates to molds for pressure casting and a method of casting in connection therewith.

The invention relates particularly to upright molds mounted on cars and moving into and past a pouring station at which the molds are filled, each mold being made of separable parts, the invention also including power means for moving the mold parts into and out of operative engagement.

A principal object of the invention is to provide mold means of the foregoing general character which is highly portable.

Another object of the invention is the attainment of great economy in that a small number of power means will sufiice, the same power means being utilized in connection with all of the molds which may be of a large number.

Another object is to provide mold means of the foregoing character which, because of the portability thereof, is maintained on a movable means, such as a car, and which includes sealing means for preventing escape of molten metal through spaces between the mold and the car.

Still another object is to provide molds of the foregoing character and novel means which hold, down the molds and provide solid support of the molds on the cars.

Other objects include provision of novel method steps including, for example, a time delay interposed between termination of the filling operation and the shut-off of the mold from the pouring tube.

Other objects and advantages of the invention will appear in the following detailed description taken in conjunction with the following drawings in which:

FIGURE 1 is a side elevational view of a mold assembly including the car for carrying the mold along the intended path;

FIGURE la is a detail view taken at line 1a1a of FIGURE 1;

FIGURE 1b is a detail view of a clamp nut used in clamping the parts of the mold of FIGURE 1;

FIGURE 2 is a top view of the assembly of FIGURE 1;

FIGURE 3 is a fragmentary sectional view taken at line 33 of FIGURE 2;

FIGURE 4 is a perspective view of one form of power means for moving the mold on the car;

FIGURE 5 is a diagrammatic view of a plurality of mold assemblies in respective positions assumed in successive movement along a track; and

FIGURE 6 is a diagrammatic view illustrating one mold 3,370,649 Patented F eb. 27, 1968 assembly in different positions along a track, showing the relative positions of the mold blocks on the car in the different positions of the assembly.

Referring now in detail to the drawings, attention is directed first to FIGURES 1 and 2 showing the mold of the invention in its entirety, and in the assembly in which it is incorporated, including a car for supporting the mold as well as framework for supporting the mold parts in' proper position on the car. The mold is indicated in its entirety at 10 and it includes two main separable parts 12 and 14 movable into and out of operative inter-engagement. FIGURES 1 and 2 show these parts in such engagement while FIGURE 6 shows the mold parts separated in two of the positions thereof as will be described in detail hereinbelow. Each mold part 12, 14 includes a graphite block 16, the parting line between which is indicated at 18, the arrangement preferably including male and female elements 18a and 18b respectively (FIG. 2), to facilitate registering the mold parts. Each graphite block is mounted in a framework including a pair of vertical angle irons 20, these four angle irons being disposed at the respective corners of the mold. Suitable conformations are made in one side, and their swinging ends have latching engagement with the opposite frame angle irons 20. Secured to the swinging end is a threaded rod 30 on which is threaded a clamp nut 32, including a large outer polygonal portion 34, a smaller inner tubular portion 36 and a chamfer 38 therebetween (FIG. 1b). A clamp bracket 39 is secured to the adjacent angle iron 20 (FIG. 1a) having an upward-1y opening notch 40 around the lower end of which is a chamfer 41. The arm is latched by swinging its free end into the notch 40, after having loosened the nut if it was not loose, and then tightening the nut; the chamfer 38 on the nut thereupon engages in the chamfer on the bracket, and a positive clamping action is provided. An additional advantage of this arrangement is that compensation is provided, for reduction in dimension of the graphite blocks which are resurfaced after wear or damage has occurred. If desired, the arms 24 may be provided with a plurality of apertures 42 selectively receiving the pins 26 for making similar adjustment.

The mold 10 illustrated herein is designed for casting relatively long billets and, as such, is of relatively tall proportions. The mold is arranged for sliding movementalong the surface of the car 44 on which it is supported and to maintain the mold in proper position thereon during such sliding movements, a framework indicated in its entirety at 46 is provided. This framework includes an upright frame structure 43 and lower support bars 50 mounted therein on opposite sides of the mold. The frame structure includes a plurality of upright members 52 of suitable form and dimensions which may be four in number, and an additional support bar 51 is provided on one side of the mold, adjacent the upper portion of the mold. The support bar 51 retains the mold against tipping while the lower support bars 50 perform the additional function of holding the mold down lightly on the car deck. These support bars are mounted in bearings or supporting elements 54 and 55 secured to the upright members 52 and are received in tubular bearings 56 and 57 mounted on the angle irons 20 of the mold parts.

The upright members 52 are positioned apart longitudinally of the car and the support bars 5% and 51 are of sutficient length to enable the assembled mold to be moved bodily along the car, and in separate movements, in which the mold parts are separated to remove the article cast therein. The lower support bars 50 are located at appropriate height, and are'of such characteristics as to hold the moldparts against the car deck with proper pressure at all locations of the mold parts.

The car 44 includes a top supporting deck 58 having a plane upper surface upon which the mold is supported. The mold assembly includes a heat sink 60 in the form of a plate, made up of separable parts, interposed between the mold and the car deck 58. This plate is of high heat conductivity and preferably is of copper which possesses a substantially higher degree of heat conductivity than the graphite blocks of the mold. The parts of this plate 60 are secured to the respective mold parts by suitable means such as angles 62- secu-red to the plate parts and respective elements of the angles 20.

v The plate 69 has an opening in register with and correspondingly shaped and dimensioned to the aperture of the mold which is indicated at 64 in FIGURE 2, the shape of which is of course determined by the intended shape of the cast article.

I The car 44 includes wheels 66 riding on tracks 68. A pouring station is indicated at FIGURE 1 in which a pouring tube 70 is positioned for pouring into the mold, the pouring tube being connected with a pressure casting ladle indicated diagrammatically at 72.

The power means for moving the mold, referred to above, are illustrated best in FIGURES 2, 3 and 4, and preferably are hydraulic ram type devices indicated at 74 and each of which includes a cylinder 76 and a piston 78. The ram means are of two different types, one of which, 74a, shown in FIGURE 2, is of the pusher type, while the other, 745, shown in FIGURE 4, is of the puller type. In the ram means 74a the piston 78 has a head 78a which merely loosely engages the mold for pushing it, while in the other ram, 7412, the piston 78 has a head 78b which includes a hook for hooking on a cooperating element on the mold for pulling the mold or mold part.

The ram means are detachably mounted in themold assembly in cradle means 80 and 82 mounted on the car. The cradle 80 includes brackets 84 having set screws 86 therein respectively engageable with opposite surfaces of a base plate 88 of the ram means. The ram means (e.g. at the right hand end of FIG. 2) is put in position by inserting the base plate 88 between opposed set screws with the piston 78 directed for engaging the mold and so engaging the mold when the piston is extended. The mold frame includes an adapter 90 having a pin 92' therein for adapting the puller type ram means (FIG. 4) but the adapter also serves as a means through which the pusher type piston can engage the mold. I

At the other end of the mold assembly (left end, FIG. 2) the cradle 82 includes additional brackets 84 for adapting both types of rams, namely 74a of FIGURE 2 or 74b of FIGURE 4. In the case of the ram 74a, the base plate 88 is butted against the outer set screws 86. This cradle 82 is particularly adapted for accommodating the puller ram 74b in the use of which the base plate 88 thereof is positioned between opposed set'screws 86b and 860, and' the hook 78b is hooked over the pin 92 and thus in position for pulling the mold or the correspondingmold part.

FIGURE 5 shows a succession of moldassemblies and cars. These cars and mold assemblies are moved along the track 68 by suitable power means (not shown) to a pouring station indicated at 94, over and in register with the pouring tube 70. After each mold is filled, the car is moved along the track to the position at the left hand end of FIGURE 5 and another one brought into pouring position.

FIGURE 6 illustrates a plurality of positions of a single car and mold. In connection with FIGURE6, it may be assumed that a pouring station is at about the point 94a that position, these rams are put in position in the assem bly as described above. Upon actuation and consequent extension of the rams, the mold parts are moved together by the pusher rams 74a to the position shown in position b after which the clamping arms 24 (FIGURE 1) are swung into clamping position shown in" that figure.

The car is then removed to the pouring position, position 0, if it is not at that time so posiiioned, and the pouring operation is performed. After completion of the pouring operation (see also below) a pusher ram 740 is actuated, for example, as indicated in position 0, with the mold parts remaining clamped together, whereupon the mold as a whole is forced out of registry with the pouring opening through the car, cutting oif the mold from the pouring tube. It will be understood that the mold parts maybe moved into inter-engagement before the mold assembly reaches the pouring station or while it is at it, placing the cavity in the mold in register with the pouring tube. Thus, the same single pair of rams 74a, at a fixed location, are utilized in each and all of the first three positions, a, b,

and c.

After the mold is moved to cut-01f position, on the car, shown in position c, the mold is permitted to cool. For this purpose, the ram 74a is detached from the mold and the latter is then moved out of pouring position, to enable another mold to be moved into the pouring station during the relatively longer period required for cooling of previously poured mold. This latter position is indicated at position d. After the mold is cooled the desired extent, a second pair of rams are applied to the car, in this case rams 74b are hooked on the respective pins 92 and, upon operation of thepower means 9612 the rams are contracted, resulting in separation of the mold parts after having first unlatched the clamping arms 24 (FIG= URE l). The cast article 98 thus produced is shown at 98 in FIGURE 6, at position d. These latter ram means 741) as stated above are detachably mounted on the car and thus a single pair of such rams at a fixed location will suflice for separating all of the molds.

The metallic heat sink plate 60 serves as a means for quickly freezing the molten metal in engagement therewith and thisfeature together with the solid hold-down of the mold by the hold down bars prevents the for.- mation of fins between the mold and plate and between the plate and the'car deck 58. The secure holding down which includes maintaining the mold in accurate position notwithstanding its relatively great height, and preventing any tipping or tilting thereof, aids in preventing any fins forming or running out occurring. at the points mentioned.

The cut-elf movement of the mold need be no greater than the maximum dimension of the mold cavity. in the direction of the movement. The movement of the mold should be as smooth and continuous as possible, this being accomplished by the effective holding down of the mold and smooth and continuous movement of the pistons which preferably is on the order of six inches 'per second. Movement at a faster rate may tend to produce an erraticmovement while movement at a slower rate may enable a binding action to take place at the plane of shear. v

The use of a metallic heat sink plate eliminates any cracking or breaking of the graphite which is relatively weak and brittle as may be the case if such plate were not used.

The method of this invention also preferably incorporates a time delay between termination of the pouring operation and the cut-01f movement. It has been found that a time delay of on the order of one second is satisfactory. This time delay permits thesystem to at least partially dissipate the kinetic energy of the rising metal in the pressure system. The force of this kinetic energy could have the elfect of running thin sections at the meeting planes of the parts of the mold assembly.

While I have disclosed and claimed herein a certain preferred form of the invention, it will be understood that changes may be made within the scope of the appended claims.

I claim:

1. A method of casting comprising the steps of providing a plurality of molds each including separable parts forming a cavity therebetween, closing successive molds by a first power means, moving the molds successively into a pouring station, pressure pouring each mold in said pouring station, moving the closed mold as a whole in cutotf movement at the pouring station by said first power means, removing the mold from the pouring station and permitting the cast article to cool, and then separating the parts of the molds by a second power means to re move the cast article therefrom.

2. The method set out in claim 1 wherein the moving of the mold after the filling operation when the mold is assembled together in a unit is at a rate on the order of 6 inches per second.

3. A method of pressure casting in a mold having a bottom opening comprising supporting the mold on a support having a pouring opening, placing the mold in a,

position with the bottom opening thereof in register with the pouring opening in the support, pressure filling the mold, moving the mold along the support to out 01f the mold from the pouring opening, and maintaining the force of engagement between the mold and support sufficiently great to prevent the formation of fins or run out in the spaces between the mold and the support.

4. The method set out in claim 3 in conjunction with the step of interposing a time delay between termination of the filling operation and cut-oil movement of the mold.

5. The method set out in claim 4 wherein said time delay period is on the order of one second.

References Cited UNITED STATES PATENTS 416,450 12/1889 Dunn 164328 1,515,163 11/1924 Myers 164l21 1,582,252 9/1926 Dodson 164264 1,925,495 9/1933 Nichols et al. 164327 3,032,841 5/1962 Sylvester 164119 3,262,164 7/1966 Meves 164341 1,929,538 10/1933 Spikeman et al 198-45 I. SPENCER OVERHOLSER, Primary Examiner. R. S. ANNEAR, Assistant Examiner. 

